Lithium-ion batteries

Abstract

Improved lithium-ion batteries in which the cathode comprises particles that include (i) transition metal grains having a grain size no greater than about 50 nanometers; and (ii) lithium-containing grains selected from the group consisting of lithium oxides, lithium sulfides, lithium halides (e.g., chloride, bromides, iodides, or fluorides), and combinations thereof.

What is claimed is:  
     
       1. A lithium-ion battery comprising: 
       (a) a cathode comprising particles that include:  
       (i) transition metal grains having a grain size no greater than about 50 nanometers; and  
       (ii) lithium-containing grains selected from the group consisting of lithium oxides, lithium sulfides, lithium halides, and combinations thereof;  
       (b) an anode other than lithium metal; and  
       (c) an electrolyte.  
     
     
       2. A lithium-ion battery according to  claim 1  wherein said lithium-containing grains have a grain size no greater than about 50 nanometers. 
     
     
       3. A lithium-ion battery according to  claim 1  wherein said lithium-containing grains comprise lithium oxides. 
     
     
       4. A lithium-ion battery according to  claim 1  wherein said lithium-containing grains comprise lithium sulfides. 
     
     
       5. A lithium-ion battery according to  claim 1  wherein said lithium-containing grains comprise lithium halides. 
     
     
       6. A lithium-ion battery according to  claim 1  wherein said transition metal grains have a grain size no greater than about 20 nanometers. 
     
     
       7. A lithium-ion battery according to  claim 1  wherein said transition metal grains are selected from the group consisting of iron, cobalt, chromium, nickel, vanadium, manganese, copper, zinc, zirconium, molybdenum, niobium, and combinations thereof. 
     
     
       8. A lithium-ion battery according to  claim 1  wherein said transition metal grains comprise iron grains. 
     
     
       9. A lithium-ion battery according to  claim 1  wherein said transition metal grains comprise cobalt grains. 
     
     
       10. A lithium-ion battery according to  claim 1  wherein said cathode further comprises a lithium transition metal oxide admixed with said particles. 
     
     
       11. A lithium-ion battery according to  claim 10  wherein said lithium transition metal oxide comprises lithium cobalt dioxide. 
     
     
       12. A lithium-ion battery according to  claim 1  wherein said particles have diameters ranging from about 0.01 microns to about 30 microns. 
     
     
       13. A lithium-ion battery comprising: 
       (a) a cathode comprising particles that include:  
       (i) transition metal grains having a grain size no greater than about 50 nanometers; and  
       (ii) lithium-containing grains selected from the group consisting of lithium sulfides, lithium halides, and combinations thereof;  
       (b) an anode; and  
       (c) an electrolyte.  
     
     
       14. A lithium-ion battery according to  claim 13  wherein said lithium-containing grains have a grain size no greater than about 50 nanometers. 
     
     
       15. A lithium-ion battery according to  claim 13  wherein said lithium-containing grains comprise lithium sulfides. 
     
     
       16. A lithium-ion battery according to  claim 13  wherein said lithium-containing grains comprise lithium halides. 
     
     
       17. A lithium-ion battery according to  claim 13  wherein said transition metal grains have a grain size no greater than about 20 nanometers. 
     
     
       18. A lithium-ion battery according to  claim 13  wherein said transition metal grains are selected from the group consisting of iron, cobalt, chromium, nickel, vanadium, manganese, copper, zinc, zirconium, molybdenum, niobium, and combinations thereof. 
     
     
       19. A lithium-ion battery according to  claim 13  wherein said transition metal grains comprise iron grains. 
     
     
       20. A lithium-ion battery according to  claim 13  wherein said transition metal grains comprise cobalt grains. 
     
     
       21. A lithium-ion battery according to  claim 13  wherein said cathode further comprises a lithium transition metal oxide admixed with said particles. 
     
     
       22. A lithium-ion battery according to  claim 21  wherein said lithium transition metal oxide comprises lithium cobalt dioxide. 
     
     
       23. A lithium-ion battery according to  claim 13  wherein said particles have diameters ranging from about 0.01 microns to about 30 microns. 
     
     
       24. A process for preparing a lithium-ion battery comprising: 
       (a) preparing a cathode comprising particles that include:  
       (i) transition metal grains having a grain size no greater than about 50 nanometers; and  
       (ii) lithium-containing grains selected from the group consisting of lithium oxides, lithium sulfides, lithium halides, and combinations thereof; and  
       (b) combining said cathode with an electrolyte and an anode to form a lithium-ion battery.  
     
     
       25. A process according to  claim 24  comprising preparing said cathode by ball milling a mixture that includes (a) a transition metal and (b) a lithium-containing compound selected from the group consisting of lithium oxides, lithium sulfides, lithium halides, and combinations thereof.